Implantable electrophysiology lead body

ABSTRACT

The invention is an electrophysiology lead body comprising two or more longitudinal elements, each having an outer surface, the longitudinal elements comprising electrical insulation material, the electrical insulation material consisting essentially of fluoropolymer; at least one conductor disposed within at least one of the longitudinal elements; and a cover consisting essentially of fluoropolymer, wherein the cover surrounds the longitudinal elements.

RELATED APPLICATION

The present application is a continuation application of U.S. Ser. No.11/269,511 filed Nov. 7, 2005, is now U.S. Pat. No. 7,630,749.

BACKGROUND OF THE INVENTION

This invention relates to the field of medical electrical lead bodiesfor use with various implantable electronic sensing and stimulationdevices such as cardiac pacemakers, implantable cardioverterdefibrillators and neurostimulators, and to the method of making suchimplantable lead bodies.

Implantable medical electrical stimulation and/or sensing leads are wellknown in the fields of cardiology and neurology. Stimulation leadstransmit therapeutic energy from an electrical pulse generator to therespective tissue or nerve. Sensing leads transmit electrical signalsfrom tissue to a remote sensor. Common applications in cardiologyinclude the treatment of various arrhythmia, (e.g. bradycardia, andtachycardia). Applications in neurology include the treatmentParkinson's Disease, epilepsy, and chronic back pain. All such medicalelectrical leads are herein referred to as “Implantable Leads.”

Implantable leads must have excellent mechanical integrity, electricalisolation between circuits, biocompatibility, and must be flexibleenough to accommodate physiologic geometry. Implantable leads must alsobe durable enough to accommodate the repeated flexure due to attachmentand dynamic affects of anatomical features, e.g. a beating heart, aspinal cord, neck, a peripheral nerve, etc.

Known leads for use with implantable electrical stimulation devices suchas cardiac pacemakers, implanted defibrillators, and neurostimulationdevices are typically constructed of a lead body having an electrodeassembly at the distal end, and a connector assembly at the proximal endof the lead body to connect to a pulse generator.

A lead body consists of at least one insulated electrical conductor andan outer insulation layer of tubular form coaxially surrounding theelectrical conductor. Current lead body constructions for cardiac andneurological applications generally fall into two categories, coaxialand multilumen designs. A coaxial lead body typically consists of one ormore helically wound coils, concentric to one another. Each coil isseparated by a tubular form of insulation.

Multilumen constructions typically consist of a silicone extrusion witha desired cross section to house a combination of helically wound coilsand conductors. In either coaxial or multilumen construction, afluoropolymer material, such as Ethylene Tetrafluoroethylene (ETFE) isapplied to the conductor materials. This material acts as a chemicalbarrier to help prevent metal ion oxidation—a reaction of the metalconductors which occurs from the release of hydrogen peroxide frommacrophages.

The implantable leads described above have several disadvantages. Due tothe softness of silicone, lead bodies made from that material are proneto damage during implantation and often fail (in-vivo) mechanically dueto tearing, abrasion, and depression. Depression is a compressive forceapplied to the lead which causes the material to fracture. Siliconeleads may also result in cases of acute allergic responses in somepatients.

Polyurethane materials are frequently used as an alternative to siliconefor added mechanical strength and lower coefficient of friction.Polyurethanes have been used in direct replacement of silicone and/or asan outer covering, or sheath for leads. Polyurethane materials and therespective leads have been known to fail due to environmental stresscracking resulting from metal ion oxidation which ultimately leads tomaterial delamination. Such failures are known to result in pieces ofinsulation being released into the blood stream creating a high risk ofadverse affects, including ischemic stroke.

Implantable lead wires using insulation materials other than theconventional silicones and polyurethanes have also been suggested. U.S.Pat. No. 4,573,480 describes an implantable electrode lead body in theform of a helically wound conductor having a tubular insulating layersurrounding the wire in which the tubular insulating layer is porouspolytetrafluoroethylene (herein after PTFE) having a pore size limitedto a maximum size described as “being essentially impervious to bodyfluids to prevent tissue ingrowth.” This patent also teaches that thetubular porous PTFE insulating layer may alternatively be provided withan outer covering of smooth impervious material.

As the design of implantable electrical leads has progressed, there hasbeen a general trend toward reduction in the diameter of the lead body,with further reduction desired. A lead of small body diameter may reducethe risk of internal trauma and infection, permit improved navigationthrough potentially tortuous geometry and simplify placement in smallanatomical features. However, maintaining adequate mechanical integrity,biocompatibility, and electrical performance, which remain critical forpatient safety and device effectiveness, are increasingly difficult withreductions in diameter.

SUMMARY OF THE INVENTION

In one aspect, the invention is an electrophysiology lead bodycomprising two or more longitudinal elements, each having an outersurface, the longitudinal elements comprising electrical insulationmaterial, the electrical insulation material consisting essentially offluoropolymer; at least one conductor disposed within at least one ofthe longitudinal elements; and a cover consisting essentially offluoropolymer, wherein the cover surrounds the longitudinal elements.

According to another aspect, the invention includes an electrophysiologylead body comprising two or more longitudinal elements, the longitudinalelements comprising an electrical insulation material being less thanabout 0.003 inches thick and having a voltage strength of at least about8000 VDC/mil; at least one conductor disposed within one of thelongitudinal elements; and a cover surrounding the longitudinalelements, in which the electrophysiology lead body has a bendingstiffness of less than about 10 g.

In yet another aspect, the invention provides an electrophysiology leadbody comprising: two or more longitudinal elements, the longitudinalelements comprising an electrical insulation material being less thanabout 0.003 inches thick and having a voltage strength of at least about8000 VDC/mil; at least one conductor disposed within one of thelongitudinal elements; and a cover surrounding the longitudinalelements, in which the electrophysiology lead body has a bending radiusof less than 0.5 inches.

In still another aspect, the invention comprises an electrophysiologylead body comprising two or more longitudinal elements, the longitudinalelements comprising an electrical insulation material being less thanabout 0.003 inches thick and having a voltage strength of at least about8000 VDC/mil; at least one conductor disposed within one of thelongitudinal elements; and a cover surrounding the longitudinalelements, in which the electrophysiology lead body has a bendingstiffness of less than about 10 g

In another aspect, the invention provides an electrophysiology lead bodycomprising two or more longitudinal elements each having an outersurface, the longitudinal elements comprising an electrically insulatingmaterial having a matrix tensile strength of at least 10,000 psi in atleast one orthogonal direction; a conductor disposed within at least oneof the longitudinal elements; and a cover surrounding the longitudinalelements, the cover comprising insulation material having a matrixtensile strength of at least 10,000 psi in at least one orthogonaldirection.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of implantable lead of the presentinvention having three longitudinal elements: a lumen and two insulatedconductors.

FIG. 2 shows a perspective view of a lead body in accordance with thepresent invention wherein the longitudinal elements include electricallyinsulated conductors helically wrapped around a lumen.

FIG. 3 shows a helically wound conductor coil disposed within the lumenof a lead body in accordance with one aspect of the invention.

FIG. 4 shows a cross section of an alternative embodiment wherein thetwo longitudinal elements are insulated conductors.

FIG. 5 shows another aspect of the invention, showing anelectrophyisiology lead body disposed within a sheath.

FIG. 6 shows in cross-section another aspect of the invention, in whichan all fluoropolymer lead body includes 8 conductors disposed around alumen.

FIG. 7 shows the test apparatus for measuring bending radius.

FIG. 8 reflects the test apparatus for measuring bending stiffness.

DETAILED DESCRIPTION OF THE INVENTION

One embodiment of the implantable electrophysiology lead body accordingto the present invention is depicted in FIG. 1 and includes at least twolongitudinal elements. At least one longitudinal element (12, 12 a) isan insulated conductor comprising a conductive material (13, 13 a) andan electrically insulating fluoropolymer material (15, 15 a) coaxiallycovering the conductive material. Optionally, the lead body may includeother longitudinal or essentially parallel elements, such as one or morehollow tubes or lumen, wires, guide wires, fibers and the like (each a“longitudinal element”). Longitudinal elements comprise fluoropolymerinsulation material and can have any cross-sectional shape, includingbut not limited to profiles that are circular, oval, triangular, square,polygon shaped or random shaped.

The term “essentially parallel” as applied to more than one longitudinalelement, includes a “side-by-side” relationship (as shown in FIG. 1, aswell as configurations that have longitudinally extending elements in ahelical or “twisted” relationship as shown in FIG. 2 and describedbelow.

Fluoropolymer insulation materials useful in the present invention haveboth high tensile strength and high dielectric or voltage strength. Thehigh tensile and dielectric strength of the materials enables the use ofvery thin layers so that lead bodies according to the present inventioncan be surprisingly small. The highly flexible lead bodies have smallbending radii and are substantially kink-resistant.

The fluoropolymer insulation materials are preferably constructed from athin tape made from fluoropolymer film. Suitable fluoropolymer filmsinclude, for example, fluorinated ethylene propylene (FEP), ethylenetetrafluoroethylene (ETFE) and chemical modifications thereof such asEFEP (available from Daikin America, Inc., under the trade markNEOFLON), perfluoro alkoxy resin (PFA), fluoroelastomers, etc. Porousfluoropolymers, optionally provided with a thin, non-porous coating, maybe advantageously used because of their excellent flexibility.Preferably, the fluoropolymer film is ePTFE. Suitable ePTFE films can bemade as taught by U.S. Pat. Nos. 3,953,566 and 4,187,390 to Gore andU.S. Pat. No. 5,476,589 to Bacino. Such fluoropolymer films aregenerally porous, flexible, and strong.

Most preferably, however, the fluoropolymer film is a compositecomprising at least one layer of non-porous ePTFE. Non-porous ePTFE iscommercially available in tape form from W.L. Gore & Associates, Newark,Del. Such non-porous ePTFE is biocompatible and combines dielectricstrength of up to 8000 Vdc/mil with exceptional mechanical performance.These tapes are also characterized by high tensile strength andexcellent abrasion and compression resistance. Tapes useful in thepresent invention have a matrix tensile strength of at least about10,000 psi in one orthoganal direction.

The fluoropolymer film may advantageously be provided with a porous ornon-porous coating of a thermoplastic such as a thermoplasticfluoropolymer, preferably fluorinated ethylene propylene (FEP). Thus,the film may also comprise a fluoropolymer laminate. Lamination can beachieved by adhering or co-joining other films, e.g., by thermally,chemically or mechanically bonding ePTFE to other materials.Specifically, the laminate includes one or more fluoropolymer sheets orfilms such as FEP, EFEP, PFA, PTFE, THV and other suitablefluoropolymers. Laminates comprising ePTFE and FEP films are taught inU.S. Pat. No. 6,159,565, to Campbell et al. commonly assigned herewith.

It may also be desirable to modify the fluoropolymer films used in thepresent invention by providing various fillers, also referred to asadditives, to the film. In the case of porous polymers such as ePTFEfilm, fillers can be imbibed into the porosity of the film by knownmethods, such as the methods taught by U.S. Pat. No. 5,879,794, toKorleski. Suitable fillers include, for example, fillers in particulateand/or fiber form and can be elastomers, ceramics, metals, metalloids,carbon, and combinations thereof. Particularly useful fillers include,for example, radiopaque materials, such as certain metals (e.g. bariumalloys) and carbon. The fillers can be used in combination with desiredadhesive materials when imbibed into the porosity of the polymer film.It may also be desirable to metalize the film or at least a portionthereof.

A filler may be included in the matrix of the polymer itself, orcontained within the voids defined by the polymeric structure, or both.Desirable fillers may also include colorants, medicants,anti-microbials, antibiotics, antibacterial agents, anti-inflammatoryagents, hemostatic agents, analgesics, elastomers and mixtures thereof.

The fluoropolymer insulation material is advantageously tape-wrappedaround a conductor to form an insulated conductor. The tape may bewrapped either longitudinally or helically. For example, an insulatedconductor useful in the present invention may be made by longitudinallywrapping (or “Cigarette Wrapping”) one or more layers of non-porousexpanded PTFE film about a conductor. The film should be of length atleast equal to the desired length of the conductor, and of adequatewidth to allow the film to be fully wrapped around the conductor surfacethereby resulting in a tubular insulative covering of longitudinallyoriented film. Alternatively, the film may be of adequate width to allowwrapping at least twice around the surface of the conductor if desired,thereby resulting in at least two layers of film. Preferably, the tapemay be wrapped helically with successive wraps in the same or oppositedirections. Combinations of helical and longitudinal wrapping may alsobe advantageously used.

Lead bodies of the present invention may include other longitudinalelements such as a lumen. A lumen may be made from a variety of thin,flexible fluoropolymer materials in tape form. Porous fluoropolymers,optionally provided with a thin, non-porous coating, may beadvantageously used because of their excellent flexibility. Afluoropolymer lumen is preferably made by wrapping a porous expandedPTFE (ePTFE) tape that has been provided with a porous or non-porouscoating of a thermoplastic fluoropolymer as described previously, arounda mandrel. More preferably, the lumen is a composite, constructed bywrapping tapes of porous expanded PTFE and non-porous ePTFE.

The thin-walled tubular lumen is most preferably made from an FEP-coatednon porous ePTFE film that has been cut into a tape and helicallywrapped on a mandrel with the Fluoropolymer adhesive placed on theexterior of the wrapping. The non porous ePTFE layer is then coveredwith a porous ePTFE.

The helically-wrapped mandrell is then placed into an oven for asuitable time to thermally bond the overlapped edges of the helicalwrapping together, thereby forming a tube. After removal from the ovenand cooling, the resulting tube is removed from the mandrel.

The insulated conductors may include solid metal conductors, having around or flat cross section, coils of stranded wires or drawn filledtubular conductors wrapped with fluoropolymer insulation material.

The conductive metals that are useful are well known in the art and mayinclude any bio-compatible and bio-stable electrically conductivematerial that is fatigue and corrosion resistant such as gold, silver,stainless steel, platinum and platinum alloys, titanium and titaniumalloys, tantalum, cobalt alloys, copper alloys, silver alloys andmagnesium nickel alloys and combinations thereof. High density material,such as platinum or platinum alloys may be used to enhance fluoroscopyvisibility of the lead body. MP35N, a Nickel-Cobalt base alloy that hasultra high strength, and toughness is preferred. The conductors may havesurfaces of base metal or may be polished, etched or textured.

The conductors preferably include stranded wires of highly flexible,electrically conductive filaments of small diameter. In a preferredembodiment, the conductor is composed of peripheral strands, which arearranged around a central strand. The strands are tightly bundled in acable-like fashion to form the conductor. However, it should beunderstood that any number of strands, or even a single strand, can beused to form the conductor of the present invention.

The outer diameter of the conductor preferably ranges from between about0.001 inch to about 0.013 inch, and diameters of about 0.002 to about0.006 inch are most preferred. It should, however, become apparent tothose skilled in the art that the outer diameter can exceed 0.013 inch.

The conductors are covered with fluoropolymer electrical insulationmaterial. The insulation thickness is preferably kept to a minimum,while still providing adequate voltage strength. Preferably, thefluoropolymer electrical insulation is in the form of a wrapped tape.Suitable insulated conductors comprising a standard MP35N conductor andnon-porous ePTFE insulation material in thicknesses of as low as about0.0005 inch are available in a variety of forms from W.L. Gore andAssociates, Inc., Newark, Del.

The longitudinal elements are surrounded by an electrically insulativefluoropolymer cover. The cover not only provides electrical insulation,but also provides strength and kink resistance to the lead body. In apreferred aspect, an electrically insulative fluoropolymer covercomprises non-porous ePTFE. More preferably, the cover comprises atleast one layer of porous ePTFE and at least one layer of non-porousePTFE.

Although any suitable fluoropolymer film can be used (such as the filmscomprising the fluoropolymers mentioned above) in combination with anysuitable adhesive (such as those mentioned above) if an adhesive isdesired, non-porous ePTFE provided with a coating of FEP is particularlypreferred. The non-porous ePTFE (or other fluoropolymer film) can be cutinto a tape and wrapped about the longitudinal elements. Thefluoropolymer adhesive can either face toward the elements, away fromthe elements, or be provided on both sides of the ePTFE film.

The fluoropolymer cover may advantageously be an ePTFE compositecomprising non-porous ePTFE and porous ePTFE. The non-porous ePTFE layercontributes to high dielectric and mechanical and voltage strength tothe lead body, while the porous ePTFE layer contributes to kinkresistance. Preferably, the porous ePTFE layer surrounds the non-porouslayer. More preferably, the cover is in the form of a first helicallywrapped non-porous ePTFE tape having a matrix tensile strength of atleast 10,000 psi and a second helically wrapped porous ePTFE tape layerpositioned over the first layer.

For example, the first layer of the cover may comprise laminated tape ofnon-porous ePTFE and a thermoplastic that is preferably a non-porousthermoplastic fluoropolymer such as FEP. The laminated tape may behelically applied with overlapping edges and with the non-porous ePTFEoriented outwardly, and the thermoplastic oriented towards the conductorgroup. The second layer of the cover may comprise an expanded PTFE filmthat has been provided with a porous or non porous thermoplasticcoating. The second layer is preferably wrapped around the first layerwith the thermoplastic material oriented to the inside.

Multiple layers of thin tape wrapping provide greater flexibility whencompared to fewer layers of thick tape. Preferably, the high strengthnon-porous ePTFE tape is less than about 0.001 inches thick, morepreferably the tape is less than about 0.0005 inches thick, and mostpreferably, less than about 0.0002 inches thick. The high strength tapelaminate is advantageously wrapped with an overlap to achieve athickness of about 0.0002 inches to about 0.003 inches. A thicker covermay yield greater dielectric strength and a stronger lead body, but willincrease the lead body diameter and stiffness.

In one aspect, the ICD lead body may be at least partially disposedwithin a sheath. As used herein, a “sheath” is a flexible tubular memberintended to improve the physical characteristics of the lead body or toadd functionality to it. A sheath may be used to improve the stiffness,tactile feel, friction or other physical characteristic, or promote anenhanced tissue response. For example, the sheath may be adapted for useas a drug or chemical delivery device. A sheath may be constructed ofconventional materials such as silicone and polyurethane and may beconstructed by molding or extruding methods known in the art.Preferably, however the sheath consists essentially of fluoropolymer andis constructed by the tape wrap process described above. The sheath mayconsist of a fluoropolymer composite, including porous and nonporousePTFE. The sheath may consist of a fluoropolymer imbibed with anelastomer.

Further variations of the inventive leads will be appreciated by theskilled artisan. By providing a tape wrap about the outer surfaces oftwo or more longitudinal elements, it is possible to obtain a secureconstruction of dissimilar elements. Moreover, such longitudinalelements can be assembled without fusing, bonding or adhering thematerials, which reduces lead body stiffness.

Turning to the Figures, shown in FIG. 1 is an electrophysiology leadbody 10 having two longitudinally extending insulated conductors (12, 12a) and a fluoropolymer composite lumen 14 joined together, in anessentially parallel fashion, by an exterior polymer tape wrap cover 16.This tape-wrapped construction also allows two or more longitudinalelements to be joined together to form a more complex assembly.Advantageously, the longitudinal elements and cover can be combinedwithout bonding the elements together or to the cover. The fluoropolymerfilm cover 16 is wrapped in an overlapping helical pattern. The filmcover 16 is shown in contact with the exterior or outer surface of theinsulated conductors 12, 12 a and the lumen 14.

Example 1

An all-fluoropolymer lead body suitable for cardiac implantation asshown in FIG. 1 was constructed in the following manner:

A thin-walled fluoropolymer composite lumen 14 was first constructed.The lumen in this example comprised a fluoropolymer laminate having aninner layer (18) of nonporous ePTFE and an outer layer (20) of porousePTFE. Non-porous ePTFE film of thickness equal to about 0.0005 inches,which was provided with a non-porous coating of FEP on one side, was cutinto tape 0.185 inches wide. The non-porous ePTFE film has a bulkdensity of about 2.1 g/cc. After cutting the coated film into a tape,the tape was wrapped on a 0.040 inch diameter silver plated coppermandrel in an overlapping fashion with the FEP coated side of the tapefacing away from the mandrel. The tape was wrapped at a pitch of about20 degrees and overlapped about 25 percent. During wrapping, the tapewas tensioned at 600 grams.

Porous ePTFE tape was wrapped around the non-porous ePTFE tape layer. A0.001 inch thick porous ePTFE film having a bulk density of about 0.9g/cc was cut into a narrow tape having a width of 0.260 inches. The tapewas wrapped at a pitch of about 20 degrees at a tension of approximately650 grams. By overlapping each successive wrap by about 50 percent, afinal porous ePTFE wrap thickness of 0.002 inches was achieved. Thetotal lumen wall thickness was about 0.003 inches. The wrapped mandrelwas then heated in a convection oven set at about 390° C. for 5 minutesto melt-bond the two helically-wrapped fluoropolymer layers together.

The longitudinal elements also include two insulated conductors (12, 12a) comprising 0.006 inch diameter MP35N stranded conductors (15, 15 a)with 0.001 inch thick fluoropolymer insulation (13, 13 a) obtained fromW. L. Gore & Associates, such as part number MCN1162. The fluoropolymerinsulation had a voltage strength of at least about 8000 Vdc/mil. Theinsulated conductors (12, 12 a) were placed adjacent to the lumen (14),with their axes roughly parallel.

The insulated conductors and fluoropolymer lumen were wrapped withnon-porous fluoropolymer tape to form a cover (16). The cover wascreated by helically wrapping non-porous ePTFE tape laminate around thelongitudinal elements. A 0.0005 inch thick ePTFE film coated on one sidewith FEP was first cut into a 0.225 inch wide tape. The tape was wrappedaround the conductors and lumen with the Fluoropolymer adhesive to theoutside of the wrap. The wrap angle was approximately 20 degrees and thetape tension was 300 g. Each wrap was overlapped approximately 25percent by the succeeding wrap, resulting in a final thickness of thesingle wrap of about 0.00075 inches. After wrapping the cover, the leadbody assembly was placed in a 390 degree oven for approximately 4minutes. The mandrel was then removed from the assembled lead body.

Although in FIG. 1 the insulated conductors are shown to besubstantially parallel to the lumen, other constructions andorientations are made possible by the tape wrap construction method. Forexample, the conductors may be helically wrapped around the lumen asshown in FIG. 2. Helical wrapping may further improve the uniformity ofthe bending properties of the finished lead body.

Furthermore, although the insulated conductors are shown to be similarin the figures, having substantially the similar inner and outerdiameters, and as having substantially circular cross sections, itshould be understood that these elements can be provided in a variety ofsizes and shapes. For example, one conductor could have a much smallerouter diameter, inner diameter, or both, as compared to the secondconductor. In another construction, additional longitudinal elementscould be constructed within the cover, such as an additional lumen sizedto accept a guidewire in a sliding relationship, or additional insulatedconductors. Moreover, by appropriately choosing the orientation of theFEP side of the fluoropolymer tape, the elements may be bonded togetherand/or bonded to the cover.

Example 2

A second lead body, constructed using techniques similar to those ofExample 1. However, this lead body is smaller and may be suitable foruse in neurologic applications. As in Example 1, the lead body comprisestwo insulated conductors (12, 12 a), but in this example, depicted inFIG. 2, the conductors are helically wrapped around a fluoropolymerlumen (14). These longitudinal elements are then covered with afluoropolymer tape wrapping (16).

A 0.020 inch inner diameter lumen (14) was constructed by wrapping asilver plated copper mandrel with porous and non-porous fluoropolymertape to construct a composite fluoropolymer tube. The lumen had an innerlayer of non-porous ePTFE tape and an outer layer of porous ePTFE tape.The two-layer construction had a total wall thickness equal to 0.001inches. First, a 0.0005 inch thick, 0.050 inch wide, non-porous ePTFEtape was wrapped at an angle of approximately 20 degrees around themandrel at a tension of 175 grams with a 25 percent overlap. The tapehad an Fluoropolymer adhesive oriented toward the outside of the wrap.Next, an 0.0002 inch thick porous ePTFE tape having a width ofapproximately 0.095 inches was wrapped at a 20 degree angle andoverlapped about 25 percent with approximately 400 grams of tension tocreate a 0.0003 inch outer layer. The tape covered mandrel was heated inan oven set at approximately 390° for five minutes.

The insulated conductors (12, 12 a) used in this example were strandedwires having a diameter of 0.003 inches. The conductors were covered bya 0.0005 inch layer of fluoropolymer insulation and obtained from W.L.Gore & Associates. The insulated conductors were helically wrappedaround the lumen at a pitch of 40 degrees.

The insulated conductors and fluoropolymer lumen were wrapped withnon-porous fluoropolymer tape to form a cover (16). A 0.0005 inch thickePTFE film coated on one side with FEP was first cut into a 0.228 inchwide tape. The tape was wrapped around the longitudinal elements withthe Fluoropolymer adhesive to the outside of the wrap. The wrap anglewas approximately 20 degrees and the tape tension was 500 g. Each wrapwas overlapped approximately 50 percent by the succeeding wrap,resulting in a final cover thickness of about 0.0015 inches. Afterwrapping the cover, the lead body assembly (10) was placed in a 390degree oven for approximately 2 minutes. The mandrel was then removedfrom the assembled lead body.

Example 3

An elastic lead body can be constructed by using porous ePTFE tape inwhich at least some of the porosity is filled with an elastomer such assilicone or urethane. As used herein, an elastic lead body means a leadbody that will deform at least 3% in the direction of an applied loadand return to its un-deformed state upon removal of such load. Methodsof preparing filled or imbibed ePTFE films are taught in U.S. Pat. No.6,673,455, and U.S. Pat. No. 6,451,396, to Zumbrum et. al and areincorporated herein by reference.

A thin-walled lumen was first constructed. The lumen comprised afluoropolymer laminate having layers of porous ePTFE imbibed withsilicone. Porous ePTFE film of thickness equal to about 0.001 inches wascut into a 0.2 inches wide tape. The tape was then wrapped on a 0.016inch diameter silver plated copper mandrel in an overlapping fashion.The tape was wrapped at a pitch of about 25 degrees and overlapped about75 percent. During wrapping, the tape was tensioned at 200 grams. Next,a 0.001 inch thick imbibed ePTFE film was cut into a narrow tape using aslit width of 0.25 inches. The tape was wrapped over the first pass oftape at a pitch of about 25 degrees at a tension of approximately 225grams. An overlap of 75 percent achieved, a final wrap thickness of0.003 inches. The total lumen wall thickness was about 0.003 inches. Themandrel was then heated in a convection oven set at approximately 150°C. for 2 minutes to cure the two helically-wrapped imbibed fluoropolymerlayers together.

As in Example 2, eight 0.003 inch diameter MP35N stranded conductorswith 0.0005 inch thick fluoropolymer insulation were obtained for theinsulated conductor group. The conductor group was again wrappedhelically around the fluoropolymer lumen.

The insulated conductors and fluoropolymer lumen were wrapped withporous, silicone-filled fluoropolymer tape to form a cover (16). Thecover was created by helically wrapping porous, silicone-imbibed ePTFEtape around the insulated conductors and the lumen. A 0.001 inch thickePTFE film was first cut into a 0.2 inch wide tape. The tape was wrappedaround the conductors and lumen. The wrap angle was approximately 25degrees and the tape tension was 200 g. An overlap of 75 percentresulted in a layer thickness of about 0.001 inches. Next, a 0.001 inchthick imbibed ePTFE film was cut into a narrow tape using a slit widthof 0.25 inches. This tape was cross wrapped over the first pass of tapeat a pitch of about 25 degrees and an overlap of 75 percent at 225 gramsof tension to achieve a layer thickness of 0.003 inches. After wrappingthe cover, the lead body assembly was placed in a 150° C. oven forapproximately 5 minutes to allow curing of the layers. The mandrel wasthen removed from the assembled lead body.

Example 4

An ICD lead body was constructed in accordance with the proceduresdescribed in Example 1. The lead body was then inserted into anall-fluoropolymer composite sheath as shown in FIG. 5. The sheath wasconstructed in the following manner:

A 0.001 inch thick ePTFE film was cut to 0.375 inches wide. The tape,was wrapped over a 0.055 inch diameter silver plated copper mandrel orthe lead body as described in example 1 at approximately 25 degrees witha 50 percent overlap. The tape was wrapped with the adhesive facing outunder a tension of 750 grams resulting in a thickness layer of 0.002inches. The second pass of the outer sheath consisted of a 0.001 inchthick ePTFE film cut into a slit width of 0.530 inch wide. The secondpass of tape was cross wrapped over the first pass at an angle of 25degrees with a 75 percent overlap and a tension of approximately 1100grams. This resulted in a layer thickness of 0.003 inches. A third passof 0.0005 inch thick non-porous ePTFE, with a coating of FEP on oneside, was slit into a width of approximately 0.560″ wide and wrapped atan angle of 20 degrees with a 75 percent overlap and a tension ofapproximately 800 grams resulting in a layer thickness of 0.0015 inches.The FEP coating was facing toward the inside. The tension on the tapewas approximately 700 grams. The non-porous ePTFE film had a bulkdensity of about 2.1 g/cc. The final construction was placed in aconvection oven set at about 390 degrees Celsius for about 3 minutes.The construction was then removed from the mandrel (if a mandrel wasused) and placed over the lead body as described in example 1.

Example 5

In yet another example an ICD lead body was constructed having 8conductors helically wrapped around a fluoropolymer lumen (14). The leadbody cross section is depicted in FIG. 6. First, a fluoropolymer lumenwas constructed in the same manner as Example 2. Eight insulatedconductors were then wrapped around the lumen in a helical fasion. Theinsulated conductors were stranded wires having a diameter of 0.003inches and were covered by a 0.0005 inch layer of fluoropolymerinsulation and obtained from W.L. Gore & Associates. The insulatedconductors were helically wrapped around the lumen at a pitch of 40degrees. The insulated conductors and fluoropolymer lumen were wrappedwith non-porous fluoropolymer tape to form a cover as described inExample 2.

The lead bodies of the present invention are produced as described aboveand comprised almost entirely of ePTFE, therefore, biocompatability isexcellent. Furthermore, a small bending radius can be easily achieved,and the flexibility is excellent. Moreover, in the preferred lead bodyof the present invention, the insulation material and cover arecomprised of a non-porous ePTFE structure. Therefore, film defects suchas pinholes are less likely to occur, and the dielectric strength isexceptional. When the lead body of the present invention is subjected toa small bending radius, for example, bending at a radius of 10 mm,excellent flexibility and elasticity are achieved, and even withrepeated bending, kinking does not occur.

The lead bodies may incorporate other elements without departing fromthe spirit of the invention. The composite construction techniques allowfor great flexibility in the design of the lead bodies. Commonly, forexample the lead will include a conductor coil (30) disposed within thefluoropolymer lumen, as depicted in FIG. 3. Other lead bodies mayinclude only insulated conductors as longitudinal elements. For example,FIG. 4 shows an inventive lead having only two insulated conductors (12,12 a) covered by a fluoropolymer wrapping (16). The stranded conductors(13) are wrapped with fluoropolymer insulation (11) and contained withina fluoropolymer cover 16.

Test Methods

Bending Radius

Samples are evaluated to determine their minimum bend radius. The testwas conducted as follows:

A sample was cut with a minimum length of 6 times the target bendingradius. As shown in FIG. 7, the ends of the sample lead body (10) areplaced in constraining devices (40, 40 a), which provide a fully fixedend condition for the sample (i.e. zero rotational or translationalfreedom). The sample length between the constraining devices is equal toat least 5 times the target radius. The sample was bent 180 degrees suchthat the end s of the lead body were separated by a distance equal tothe target radius. The sample is examined for visible kinking. Thesample is said to have met the target bend radius if no sign of kinkingappears.

Bending Stiffness

The stiffness is characterized by the force necessary to deflect asample lead body. The bending stiffness of the inventive ICD lead bodywas determined through the use of a special test fixture is depicted inFIG. 8 and FIG. 8 a. The fixture provides a means for bending a leadbody to a predetermined initial condition. The lead body is thendeflected to a final position. The force necessary to deflect the leadbody from its initial position to the final position is the lead bodystiffness and is measured in grams.

The test fixture comprises a base (70) having two guide blocks (66, 66a) and two end blocks (71, 71 a). The guide blocks (66, 66 a) containguide channels in which the lead body moves. The end blocks (71, 71 a)fix the ends of the lead body during the test. The test fixture isprepared by placing a ¼ inch diameter pin (60) between the two guideblocks (66, 66 a).

The lead body (10) is passed through holes (74, 74 a) in end blocks andthrough guide channels (64). A first end of the lead body (10) is fixedby tightening a set screw (72, 72 a) installed in the first end block(71). The opposite end of the lead body is tensioned until the lead bodyjust contacts the pin (60) and then a second mounting screw (76 a) istightened.

Next, the pin (60) is removed. In this way, a bend is formed in thecenter of the lead body. The fixture is then placed on a calibratedelectronic scale (78) and the scale is zeroed. The lead body is thenpressed downward from the top of the arch with a screw drive plunger(62). The plunger (62) has an indexing pin (not shown) or is otherwiseadapted to prevent lateral movement of the lead body during movement.The lead body is depressed until it just makes contact with the base(70) of the test fixture. The bending stiffness, in grams, is readdirectly from the electronic scale.

Matrix Tensile Strength

Matrix tensile strength of ePTFE materials including ePTFE films ismeasured using an INSTRON tensile testing machine with pneumatic cordand yarn grip jaws. The machine tested 0.25 inch wide samples using a 1inch jaw separation distance and a crosshead speed of 10 inches/minute.Matrix tensile strength of porous PTFE samples is determined by theformula:(2.2 g/cc×tensile strength)/density of tested material,where 2.2 g/cc is taken to be the density of non-porous PTFE.Voltage Strength (Dielectric Strength)

The following protocol was used to characterize the dielectric strengthof an individual Insulated Conductor:

An insulated conductor specimen of about 15 cm is prepared and arrangedsuch that the insulation material(s) are in direct contact with a salinepreconditioning and test bath. For example, assemblies comprised of morethan one insulated conductor a specimen had any outer coverings,jackets, or components, not intended to provide electrical insulationremoved such that the appropriate insulation material(s) are in directcontact with the preconditioning and test baths. Specimens werepreconditioned using a saline preconditioning bath of approximately 9g/l saline at 37° C.+/−5° C. for a minimum of 10 days. Immediately priorto testing, each specimen was rinsed in distilled or deionized water,then wiped free of surface water. After preconditioning, specimens werenot allowed to dry.

The specimens were immersed in a test bath consisting of approximately 9g/l saline at 37° C.+/−5° C. The specimens were placed not less than 50mm nor more than 200 mm from a metal reference electrode plate. Theelectrode reference plate had a minimum surface area of 500 mm². Carewas taken to ensure that the electrodes, wire ends and terminals areelectrically isolated from the test bath. All exposed metal surfaceswere kept at least 20 mm from the surface of the test bath.

The electrical continuity of each conduction path was first verified bymeasuring the DC resistance using a resistance meter, such as a Fluke189 digital multimeter (Fluke Corporation, Everett, Wash.). The DCvoltage strength of insulation was tested for each insulated conductor.A test voltage was applied to one insulated conductor and the leakagerate was measured between that insulated conductor and the referenceelectrode. The leakage rate between the insulated conductor carrying thetest voltage and all other insulated conductors was also measured.

An electrical safety analyzer such as the QuadTech Guardian 6000(Quadtech, Inc., Maynard, Mass.) series testers was used to apply thetest voltage, and to measure leakage current. The full test voltage wasattained within 0.1 to 5 seconds of test initiation and was maintainedfor at least 15 seconds.

Insulated conductor insulation passed the voltage strength test only ifit met the following criteria: 1) The leakage current measured betweeneach insulated conductor and the reference electrode was less than orequal to 2 mA; 2) The leakage current measured between any two insulatedconductors does not exceed 2 mA. The lumen electrical insulation testrequired that the leakage between the inner and out surfaces of thelumen was less than or equal to 2 mA.

TEST RESULTS Lead Body Lumen Voltage Minimum Bending Bending VoltageStrength Radius Stiffness Strength (Min. Vdc) (inches) (grams) (Min.Vdc) Example 1 8,000 VDC ½ 10 3,500 Example 2 4,000 VDC   3/16 4 3,500Example 3 4,000 VDC ⅛ 5 10,000 Example 4 8,000 VDC ½ 10 3,500 Example 54,000 VDC ¼ 6 3,500

While particular embodiments of the present invention have beenillustrated and described herein, the present invention should not belimited to such illustrations and descriptions. It should be apparentthat changes and modifications may be incorporated and embodied as partof the present invention within the scope of the following claims.

The invention claimed is:
 1. An electrophysiology lead body comprising:a) two or more longitudinal elements, each having an outer surface, saidlongitudinal elements comprising electrical insulation material, saidinsulation material consisting of wrapped fluoropolymer; b) at least oneconductor disposed within at least one of said longitudinal elements;and c) a cover, said cover consisting of wrapped fluoropolymer, whereinsaid cover surrounds said longitudinal elements.
 2. Theelectrophysiology lead body of claim 1, in which the conductor comprisesa helical coil.
 3. The electrophysiology lead body of claim 1, in whichsaid insulation material comprises ePTFE.
 4. The electrophysiology leadbody of claim 3, in which aid insulation material comprises non-porousePTFE.
 5. The electrophysiology lead body of claim 3 in which saidinsulation material comprises ePTFE and a thermoplastic.
 6. Theelectrophysiology lead body of claim 1, in which said cover comprisesePTFE.
 7. The electrophysiology lead body of claim 6, in which saidcover comprises non-porous ePTFE.
 8. The electrophysiology lead body ofclaim 6 in which said cover comprises ePTFE and a thermoplastic.
 9. Theelectrophysiology lead body of claim 6, in which said cover comprises afluoropolymer laminate, said laminate including a layer of porous ePTFEand a layer of non-porous ePTFE.
 10. The electrophysiology lead body ofclaim 1, in which said fluoropolymer is film is helically wrapped aroundsaid conductor.
 11. The electrophysiology lead body of claim 1, in whichsaid cover comprises fluoropolymer film wrapped about the outer surfaceof said longitudinal elements.
 12. The electrophysiology lead body ofclaim 11, in which the film is helically wrapped about the outer surfaceof said longitudinal elements.
 13. The electrophysiology lead body ofclaim 1 in which the insulation material is less than about 0.003 inchesthick.
 14. The article of claim 1 in which said insulation material isless than about 0.0015 inches thick.
 15. The article of claim 1 in whichsaid insulation material is less than about 0.0005 inches thick.
 16. Thearticle of claim 1 in which said insulation material is less than about0.0002 inches thick.
 17. The electrophysiology lead body of claim 1,further comprising at least one lumen disposed within said cover, saidlumen consisting essentially of fluoropolymer.
 18. The electrophysiologylead body of claim 17, in which said lumen comprises ePTFE.
 19. Theelectrophysiology lead body of claim 18, in which said lumen comprisesnon-porous ePTFE.
 20. The electrophysiology lead body of claim 1,wherein said cover is longitudinally wrapped.
 21. The electrophysiologylead body of claim 1, wherein said cover is helically wrapped.
 22. Theelectrophysiology lead body of claim 1, wherein said at least oneconductor is stranded.
 23. The electrophysiology lead body of claim 5,wherein said thermoplastic is FEP.
 24. The electrophysiology lead bodyof claim 8, wherein said thermoplastic is FEP.